Robot AutomationTEAM 072017-2018

Nathan Casey (ECE)

Josh Tempelman(ME)

Michael Bissetta(ECE)

The Team

Alex Keizer(ME)

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Presentation Outline

Overview

Initial mechanical design

Initial electrical design

Design Change

Final mechanical design

Final electrical design

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The Customer

• Specializes in machining, assembly, inspection

• Serves wide variety of industries: automotive, office, medical, and more

• Currently uses little automation

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Project overview

• Parts are currently being produced in a lathe operated by a worker.

• The pucks are put into a lathe twice, machined to precise dimensions, and measured.

• Our task was to automate this process, decreasing cost and increasing part quality.

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Ethics and Design Norms

Delightful Harmony TransparencyTrust

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Initial design requirements

• Manufacture parts with little to no human interference

• Operate robustly and reliably

• Manufacture 120 parts per hour

• Track dimensions of finished parts

• Comply with safety standards

• All designs are owned by Prefferred Quality Services, not Team07

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Initial mechanical plan - indexing table

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Initial mechanical plan – End of Arm Tool

- Electromagentic Gripping

- Simple Bracket Configuration

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Initial electrical plan - Communication

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Initial electrical plan - Block Diagram

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Anticipated challenges

● Reliable measurements

● Consistent part grabbing

● Lack experience in networking and programming

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Project Change

3+ years of production anticipated on the part created by the cell

November 16 the OEM notified PQS that the part will bediscontinued in Q1 of 2018

PQS has assigned a new project to the team to replace this one

OEM

SUPPLIER

PQS

Old Part New Part

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New requirements

• New heavier part + how to machine it

• New table

• New electrical hardware and requirements

• No measurement system

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Lessons learned

• Scrapped ideas (ex. Gantry robot, two motors for original table design)

• Engineering in industry can be volatile

• Must be able to adapt quickly

• It is important to research deeply as well as broadly

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Safety

• Cage keeps employees away from moving parts

• Three Emergency stop buttons

• Safety Relay connects all E-stops and handles emergency procedure

• Safety mat and speaker ensures no one is near table when it rotates.

• Stack lights indicate machine state

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Finances

• Cost savings was a important factor for our customer

• With the change of project costs increased significantly and that had to be communicated to the

customer

• We updated our budget regularly and kept the customer informed on all changes

• We saved a lot of the cost by going through several robot suppliers

• We can also save cost in the future by using parts that have long lifespans

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New System Design

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Key Components:-HAAS Lathe-Fanuc Arcmate 6-Axis Robot-Rotating Part Loading Table-Part Check Ramp-Finished Part Bin-Velox Safety Caging

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New mechanical plan - indexing table

Key Components:-Oriental Motor-Polycarbonate Shields-E-stop Switch-80/20 Framing

Key Metrics/Decisions:-Modular-Cost Effective-Portability-Safety-Manufacturability

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Part Table Progress

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New mechanical plan - parts slot

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Key Components:-80/20 Framing-Low Friction Polycarbonate Slides-Housing for Electrical Hardware-Touch Screen Display

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New mechanical plan – End of Arm Tool

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Key Components:-Machined Aluminum Plumbing-Venturi Vacuum Pumps-Two Laser Distance Sensors-Proxy sensor-Homing Rods

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FEA and Calcs

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20

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New electrical design plan - power distribution

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New electrical design plan - Communication

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New electrical design plan - software

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New electrical design plan - software

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New electrical design - Progress

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Lessons learned

- Working with distributors can be difficult

- Software can have a lead time

- Inter-team communication is important

- Don’t assume things about the customer

- Solid plans make work go much faster

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Moving Forward

• Finish programing

• Wire and power all components once drops are installed

• Finish installation of arm and cage

• Begin working through test plan

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Questions

31